Peng Laihu, Xiong Xuyi, Wang Luojun
Zhejiang Provincial Key Laboratory of Modern Textile Equipment and Technology, Zhejiang Sci-Tech University, Hangzhou, 310018, Zhejiang, China.
School of Automation, Zhejiang Polytechnic University of Mechanical and Electrical Engineering, Hangzhou, 310053, Zhejiang, China.
Sci Rep. 2025 Mar 21;15(1):9750. doi: 10.1038/s41598-025-94768-7.
During the operation of the knitting underwear machine, unstable yarn tension can have adverse effects on the quality of the underwear fabric, such as uneven density and reduced resilience, which significantly diminishes the comfort and durability of the textile products. In response to the issues of slow tension response speed and low tension control accuracy in the traditional yarn feeding method of current knitting underwear machines, a tension control system has been designed for the yarn feeding process. The system employs an adaptive ADRC algorithm, which is based on fuzzy sliding mode control, to detect the real-time trend of yarn tension changes, adjust the real-time target speed of the yarn feeding motor, and then utilizes permanent magnet synchronous motor vector control technology to drive the motor operation. This reduces tension disturbances during the yarn feeding process, enhances the response speed during sudden tension changes, and achieves precise control of yarn tension. Finally, a tension controllable yarn feeding experimental platform was constructed to simulate the knitting underwear machine, and tests were conducted to evaluate the control effectiveness of the yarn feeding tension control system under various algorithm controls. The results show that the control system based on the adaptive ADRC algorithm reduces the amplitude of tension fluctuation in the yarn target tension stabilization phase by more than 33% compared to traditional PID and ADRC algorithms. The average response time is shortened by over 35%, respectively. These comparative data demonstrate that the system can enhance the stability of yarn tension control during the yarn feeding process while meeting the varying elasticity demands of different fabrics and the specific yarn feeding speed requirements of various knitting processes, ultimately ensuring fabric quality.
在针织内衣机运行过程中，纱线张力不稳定会对内衣面料质量产生不利影响，如密度不均和弹性降低，这会显著降低纺织产品的舒适度和耐用性。针对当前针织内衣机传统喂纱方式中张力响应速度慢、张力控制精度低的问题，设计了一种喂纱过程张力控制系统。该系统采用基于模糊滑模控制的自适应自抗扰控制（ADRC）算法，检测纱线张力变化的实时趋势，调整喂纱电机的实时目标速度，然后利用永磁同步电机矢量控制技术驱动电机运行。这减少了喂纱过程中的张力干扰，提高了张力突变时的响应速度，实现了对纱线张力的精确控制。最后搭建了一个可模拟针织内衣机的张力可控喂纱实验平台，并进行测试以评估喂纱张力控制系统在各种算法控制下的控制效果。结果表明，与传统PID和ADRC算法相比，基于自适应ADRC算法的控制系统在纱线目标张力稳定阶段将张力波动幅度降低了33%以上，平均响应时间分别缩短了35%以上。这些对比数据表明，该系统在满足不同面料的弹性需求和各种针织工艺的特定喂纱速度要求的同时，能够提高喂纱过程中纱线张力控制的稳定性，最终确保面料质量。
